Abnormal Wire Cutting Processing And Analysis

- Aug 21, 2018-

2. Surface quality problems


The surface quality problems of processing mainly include surface stripe, roughness is not required, and surface metamorphic layer is too thick.


(1) Surface stripes


According to the process specified by the slow wire cutting machine, if there is streaking on the surface, first of all, it depends on whether the quality of the wire is defective. It is easy to use the inferior electrode wire which is cheap on the market, and the problem of processing stripe is easy to use. Try to use genuine consumables. Similarly, the use of low-quality workpiece materials containing impurities can also result in dense streaks on the machined surface.


For the processing of tapered parts, the surface is prone to streaking, and a softer brass wire with better flexibility can be used to obtain a significant improvement. When machining a die, it often happens that a dent appears at the infeed, which can be improved by arcing in and out during programming.


Processing should ensure that the machine tool is running smoothly, the wire tension is stable, and the wire speed and tension are calibrated if necessary. The wear of the conductive block should be rotated or replaced in time to clean the upper and lower guide wire components, including the guide wire guide, the guide wire core seat, the lower guide wheel, and the guide wheel bearing.


(2) Surface roughness does not meet the requirements


For abnormal conditions where the surface is not completely polished and the surface roughness does not meet the requirements, it should be checked whether the offset of the program is reasonable. It is possible to appropriately increase the amount of material between the two knives to ensure that the last trimming can completely repair the surface of the previous processing.


A slight deformation of the cutting workpiece will also result in a surface roughness that is not satisfactory, and the surface after the trimming is partially uneven. At this time, it is necessary to control the occurrence of machining deformation. For large, thick-walled, complex-shaped, uneven-thickness mold parts, it is advisable to increase the number of cuts to reduce and remove surface defects.